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NATURAL WOOD. JIGSAW PUZZLE

The method shown here and on page 113 allows you to create three puzzles with the same basic design, but with different colors and cutting patterns. Plane three boards to a thickness of / inch and trim them to the same length and width. Aligning the edges and ends of the boards, bond them together temporarily with dabs of epoxy glue at the corners. Then draw your design directly on the top piece with a pencil, starting with a ‘/*- to {£-inch border on all sides. The design should have the same number of elements as layers—in this case, mountains, sun, and sky. This enables you to mix and match the elements, creating three differently colored puz­zles. Install a fine blade in your scroll saw; a 0.016-inch-thick and 0.043-inch-wide blade will work well. Using a hold­down to keep the workpiece from lifting off the saw table, cut along the marked lines separating the main elements (right). Feed slowly to prevent the blade from bowing; the three layers must be identical. Leave the border line intact.

Sanding the elements

Separate the three layers with a utility knife, then com­bine the nine pieces into three mountain-sun-sky groups, mixing up the colors. Working on each group individually, mark your cutting pattern directly on the wood. Each piece should have at least 3 or 4 lobes or sockets; extend the pat­tern across the border line so the frame will be part of the puzzle. Then, to give the puzzle the illusion of depth, use a spindle sander to bevel the mating edges of the puzzle. Avoid sanding off too much wood or you will end up with noticeable gaps between the pieces.

3 Cutting out the frame pieces

Once the bevels have been sanded, cut out the the frame pieces on the scroll saw. With the hold-down in position, cut along the border line and the lobe and socket marks (left), feeding the workpiece with both hands.

4

Mounting the frame pieces to a base

Cut a wood base to the same size as your puzzle, then spread some glue on the under­side of the frame pieces and position them on the base. To secure the pieces while the adhesive cures, lay a grid of clamping blocks across the assembly to distribute the pres­sure and clamp down the blocks (above).